Extendable and/or expandable foam panel constructions

ABSTRACT

By forming a plurality of separate, spaced, expansion zones in preselected areas of a foamed plastic product having a desired size and shape, a new foam plastic product is achieved which is capable of being expanded or extended in at least one direction during its use in order to accommodate dimensional changes or requirements. By forming the expansion zones in a precisely desired pattern which extends over a substantial portion of the foam plastic product, the resulting product is capable of being expanded, extended, or adjusted in at least one of its dimensions. In this way, the resulting product is quickly and easily expanded or extended in one direction to fit any desired application surface with ease and simplicity.

RELATED APPLICATIONS

This application is related to U.S. Provisional Patent Application Ser.No. 61/125,986, filed Apr. 29, 2008 entitled “EXTENDABLE AND/OREXPANDABLE FOAM PANEL CONSTRUCTIONS.”

TECHNICAL FIELD

This invention relates to enlarged, foam panel constructions and, moreparticularly, to enlarged foam constructions which are capable of beingexpanded or extended in at least one dimension whenever desired.

BACKGROUND ART

Throughout the years, an ever increasing variety of products and productareas have benefitted from the use of foam plastic materials. In thisregard, product manufacturers, suppliers, and/or shippers have foundthat foam plastic products, materials, and profiles can be employed forimproving the quality of the product being produced, as well as forsubstantially improving packing materials and product safety panelswhich are commonly used in product protection during shipment.Furthermore, due to the unique nature of foam plastic products and theability of these products to be formed in various sizes, shapes, andconfigurations, these products have enjoyed increased acceptance anduse.

As the abilities, capabilities, and versatility of foam plastic materialbecame known to individuals and corporate entities, the popularity offoam plastic products substantially increased, along with the widevariety of product areas and purposes for which foam plastic productswere employed. In this regard, foam plastic material has been used forprotecting small fragile products such as those made from glass, as wellas protecting large products made from metal or similar materials, suchas refrigerators, stoves, and the like. In these large products, foamplastic panels are often employed to peripherally surround the productand protect the outer surfaces of the product.

In addition, foam plastic materials have also been employed in numerousother products as an integral components of the product. In this area,furniture, bedding, and mattresses have employed foam plastic materialsas an integral component incorporated into the product structure itself.In this instance, foam plastic materials have proven to be effective inproviding support and integrity to the product as a replacement forcomponents which are more expensive and more difficult to employ.

In spite of the fact that foam plastic products have gained wideacceptance and use in a wide variety of applications, industries, andproduct areas, it has been recognized that the use of foam plasticproducts in many areas can be improved due to inherent physicalcharacteristics of the foam plastic materials. In this regard, one ofthe principal difficulties encountered with the use of foam plasticmaterials is the difficulty in controlling the dimensions of the foamplastic material during production, in order to assure that preciselydesired dimensions are attained. This problem has been found in the useof foam plastic panels for protecting large products, as well as in theuse of foam plastic panels in furniture products, bedding, andmattresses.

In using large foam plastic panels for these products, the overall sizeand shape of the foam plastic product is critical in being used on aparticular previously manufactured surface. However, during theproduction of the foam plastic panels, controlling a precise dimensionalsize has been found to be particularly difficult. As a result, foamplastic panels are often constructed in sizes larger than required, andthen cut or trimmed to the dimension needed for a particularapplication. Although effective, this process is more expensive, sincematerial is cut and thrown away, as well as being time-consuming andlabor intensive.

Therefore, it is a principal object of the present invention to providefoam plastic products which are capable of being constructed in a mannerwhich enables the product to possess an expandable or variablecapability enabling the size or shape of the product to be flexible inat least one direction.

Another object of the present invention is to provide foam plasticproducts having the characteristic features described above which iscapable of being produced with substantially no increase inmanufacturing costs.

A further object of the present invention is to provide foam plasticproducts having the characteristic features described above wherein theresulting product is capable of being expanded to a desired dimensionand automatically locked in that dimension.

Other and more specific objects will in part be obvious and will in partappear hereinafter.

SUMMARY OF THE INVENTION

By employing the present invention, all of the difficulties anddrawbacks found in prior art constructions have been overcome and a new,unique, foam plastic product is achieved which is capable of beingexpanded or extended in at least one direction during its use in orderto accommodate dimensional changes or requirements. In this way, foamplastic products of any size or configuration are capable of beingemployed for a wide variety of alternate purposes or applications due tothe capability of the product to be expanded in at least one dimension.As a result, foam plastic products incorporating this constructionachieve greater versatility and benefit in numerous industries,applications, and product areas, while also providing ease of use, speedand convenience during the installation process.

In accordance with the present invention, the desired foam plasticproduct is first produced using conventional manufacturing techniqueswith the overall configuration, size, and shape desired for the product.Thereafter, the foam plastic product is processed using a desiredmanufacturing method wherein a plurality of separate, spaced, expansionzones are formed in preselected areas of the product.

By forming the expansion zones in a precisely desired pattern whichextends over a substantial portion of the foam plastic product, theresulting product is capable of being expanded, extended, or adjusted inat least one of its dimensions. As a result, without degradation of theintegrity of the foam plastic product, the resulting product is quicklyand easily expanded or extended in one direction to fit any desiredapplication surface with ease and simplicity, without requiring anytrimming, cutting, or laborious procedures for achieving a desireddimension.

Typically, each expansion zone is formed by cutting through the foamproduct in a predetermined length and pattern relative to adjacent cuts.In this way, predefined areas or cut-out zones are created whenever thefoam product is moved in a particular direction.

Although the present invention can be implemented in a wide variety offorms and employed in numerous products and applications, one example ofa product which is capable of experiencing substantial improvement inproduction and manufacture due to the application of the presentinvention is found in inner spring mattresses. In the production ofinner spring mattresses, large foam panels are employed for improvingsupport and longevity of the product. Typically, these large foam panelsare placed on the surface of the inner spring assembly, positionedbetween the inner spring surface and the textile material cover whichperipherally surrounds and defines the mattress assembly. In thisregard, these large foam panels have been employed and have providedsubstantially improved mattress products.

Although the prior art foam panels have been successful in improvinginner spring mattress assemblies, the construction of these enlarged,extruded foam panels are difficult to manufacture with accurate andrepeatable dimensional tolerances. As a result, production difficultiesand product installation problems presently exist.

By employing the present invention, all of these prior art difficultiesare virtually eliminated and enlarged, extruded, foam panels are capableof being constructed having adjustable or variable dimensions, therebyenabling these panels to be employed as the top supporting panel orsurface of a mattress, and placed on the surface of the inner spring andeasily secured to the terminating edges of the inner spring assembly.Furthermore, using the enlarged extruded foam panels of the presentinvention, the panels are merely extended in one dimension in order toassure that the panels extend from one edge of the inner spring to theother edge, completely covering the desired surface and establishing thesupport for the mattress assembly.

In order to achieve this unique and previously unattainable goal, theenlarged extruded foam panels of the present invention are produced inthe generally conventional manner and then exposed to a subsequentmanufacturing operation which forms a plurality of zones in the foampanels, which enable the panel to expand and contract in at least onedimension. In this regard, it has typically been found that theexpansion zones are formed in enlarged sections, extending from the topedge to the bottom edge of the foam panels. In addition, the width ofeach expansion zone can be varied and any desired number of expansionzones can be formed at spaced intervals to each other.

Once the expansion zone formation process has been completed, theresulting foam panel construction is capable of being expanded,extended, and contracted in at least one dimension. In particular, whena plurality of expansion zones are formed in the large foam panelextending from the top edge to the bottom edge of the panel, the sideedges of the resulting panel are capable of being extended andcontracted relative to each other.

As is fully detailed herein, the formation of numerous, separate, andindependent expansion zones in spaced relationship to each other createsan elongated, expansion zone bearing section in the panel which is ableto be extended and contracted in one dimension due to the ability ofeach expansion zone to have its size or shape easily increased ordecreased. In this way, the enlarged foam panels of the presentinvention are positioned on the inner spring surface and easily adjustedin one dimension, such as its width, in order to completely extend fromone side edge of the inner spring assembly to the other side edgethereof quickly and easily, while also being secured in the desiredposition. As a result, prior art problems and difficulties arecompletely eliminated.

In forming the expansion zones of the present invention in the foampanels, each expansion zone can be formed with any desired shape orconfiguration. In general, the only requirement is that each expansionzone is separate and independent from each adjacent expansion zone,thereby creating an interconnected lattice of foam material whichperipherally surrounds the expansion zones and enables the resultingpanel structure to be extendable in at least one dimension.

In one embodiment, the interconnected lattice of foam material whichperipherally surrounds the expansion zones is formed with an inherentspring force which attempts to maintain each expansion zone in asubstantially closed configuration. As a result, the resulting foampanel is normally maintained in a compact configuration, requiring theapplication of force to extend the foam panel in the desired direction.

When the extending force is applied, the foam panel extends or expandsin the desired direction into an overall dimension sought by the user.Furthermore, the increase in the dimension of the foam panel causes eachexpansion zone to be enlarged as the dimension is increased. However, ifthe extending force is removed, the foam panel will return to itssubstantially original configuration due to the inherent spring force ofthe interconnected lattice of foam material.

In an alternate embodiment, the interconnected lattice of foam materialis constructed with a particular configuration which enables the latticeof foam material to move between two specific alternate positions. In afirst position, the lattice of foam material provides a spring forcewhich attempts to return the foam panel to its original position.However, in a second position, the lattice of foam material becomeslocked or substantially rigid in the second position, resulting in afoam panel which is maintained in a substantially stable overallexpanded dimension.

This embodiment has been found to be particularly applicable for use onproducts or applications where the foam panels peripherally surround andprotect a product being transported, and are not typically secured tothe product along the edges of the panel. As a result, by achieving afoam panel which is fixed in its overall dimension, the panels arequickly and easily placed in position and maintained where desired,protecting a particular surface of the product.

In an alternate use of this embodiment of the present invention, thepanel of foam material can be moved between its compact position and itsextended position whenever desired. As a result, the foam panel can beused for various activities or recreational purposes, such as a poolfloat, with the panel being expanded for use, and contracted into acompact position for storage. In this way, a substantially increasedbenefit is provided to the consumer.

In producing the enlarged foam panels of the present invention, severalalternative construction methods can be employed for forming the foampanel as well as the plurality of expansion zones in the panel member.Although any effective method can be employed, it has been found thatthe following methods are exemplary of the production systems that canbe used to achieve the expandable or extendable foam panel of thepresent invention.

In this regard, the formation processes for creating the foam panelmember preferably comprises one or more selected from the groupconsisting of extrusion injection molding, rotational molding,compression molding, expansion molding, and casting. In addition, theformation process for achieving the desired expansion zones in the foampanel preferably comprise one or more selected from the group consistingof water jet cutting, rotary die cutting, punch press cutting and lasercutting.

In order to fully understand the construction of the extendable foampanels of the present invention, one of the preferred manufacturingmethods is further detailed herein. In this regard, the enlarged foampanel is produced in the normal manner well known in the industry. Oncethe foam panel has been produced, the foam panel is passed through acutting die which forms the plurality of expansion zones in the panelmember. Typically, these expansion zones are most easily created byforming slots or slits in the foam panel, extending from the top surfaceto the bottom surface thereof. Furthermore, as detailed above, theexpansion zones are formed in the panel in predefined, desired sectionsof the panel, with each section preferably extending from one edge tothe opposed edge thereof.

In a typical construction using this embodiment of the forming process,the cutting die comprises either a rolling cutting die or a flat cuttingdie which enables the enlarged foam panel to be continuously passedtherethrough. In using a rolling cutting die, which has been found to bemost efficient in a continuous production operation, a pair of diemembers are cooperatively associated with each other and constructedwith a spaced zone therebetween through which the enlarged foam panel iscapable of passing.

With at least one of the cooperating die members incorporating raisedcutting elements, the desired slots or slits are formed in the foampanel as the panel passes between the cooperating rolling dies, with thearea adjacent to the slots or slits being left intact. In this way, theexpansion zones are easily formed along with the interconnected latticeof foam material surrounding the expansion zones.

Furthermore, using this production process, the desired expansion zonesare quickly and easily formed in the enlarged foam panel in theprecisely desired areas. Furthermore, once the elongated length of thefoam panel has passed between the rolling dies, the resulting product isfully produced and ready for packaging and distribution to the user.

As is evident from this disclosure, as well as in the detaileddiscussion contained below, any desired configuration, shape, ororientation can be employed for forming slots, slits, and resultingexpansion zones in the panel members. In one embodiment, the slot, slitsand resulting expansion zones can be found randomly while in anotheralternate embodiment, the slots, slits and resulting expansion zones areformed in a cooperating pattern. However, regardless of the particularconfiguration employed, the slots, slits, and/or expansion zones arepreferably staggered relative to each other in the desired direction inorder to produce an integrated lattice of foam material peripherallysurrounding the separate and independent expansion zones. In this way,the desired flexibility and expansion capabilities are most effectivelyachieved.

It has also been found that longitudinally extending, staggered straightslits/slots and/or longitudinally extending, staggered, arcuately curvedslits/slots produce the most effective expansion zones and are easilymanufactured in a controlled process. Furthermore, in the preferredembodiment, a first row of longitudinally extending staggered,slits/slots are offset relative to the second row of longitudinallyextending, staggered slots/slits. If desired, further offsetorientations can be employed for one or more additional rows. However,by employing at least two offset rows of slots/slits, a highly effectiveproduct is produced with an integrated lattice of foam peripherallysurrounding each resulting expansion zone and providing the desiredcontinuous spring force.

Finally, using an alternative construction process of the presentinvention, a greatly enlarged panel member can be achieved withoutrequired large, costly equipment to be employed. In this alternatemethod, foam panel members are constructed in the manner detailed aboveand then welded to each other along an adjacent side edge. If two panelsare welded together, this resulting product is double the size or areaof the original panel. Furthermore, by repeating this process, panels ofany size or shape can be economically produced.

The invention accordingly comprises the several steps and the relationof one or more of such steps with respect to each of the others, as wellas the article produced which possesses the features, properties, andrelation of elements, which are exemplified in the following detaileddisclosure, with the scope of the invention being indicated in theclaims.

THE DRAWINGS

For a fuller understanding of the nature and objects of the invention,reference should be had to the following detailed description taken inconnection with the accompanying drawings, in which:

FIG. 1 is a top plan view of one embodiment of the readilyextendable/expandable foam panel construction of the present invention;

FIG. 2 is a top plan view of an alternate embodiment of the readilyextendable/expandable foam panel construction of the present invention;

FIG. 3 is a top plan view of a further alternate embodiment of thereadily extendable/expandable foam panel construction of the presentinvention;

FIG. 4 is a perspective view of one embodiment of the readilyextendable/expandable foam panel construction of the present inventionforming an integral component of a mattress construction;

FIG. 5 is a perspective view of an alternate embodiment of the readilyextendable/expandable foam panel construction of the present inventionconfigured for use in an alternate mattress construction;

FIG. 6, which comprises FIGS. 6A, 6B, and 6C are all perspective viewsof an alternate embodiment of the readily extendable/expandable foampanel construction of the present invention, depicting the foam panel intwo alternate configurations between a collapsed position and a fullyextended position;

FIG. 7, which comprises FIGS. 7A, 7, 7C, and 7D, are perspective viewsof fragmentary portions of the readily extendable/expandable foam panelconstruction of the present invention depicting alternate configurationsof the panel construction during its movement between a fully compact,collapsed position into a fully extended position;

FIG. 8, which comprises FIGS. 8A, 8B, and 8C are perspective views ofvarious alternate constructions and configurations of a furtheralternate embodiment of the present invention.

FIG. 9 which comprises FIGS. 9A and 9B are perspective views of anelongated foam profile extrusion and cross-sectional panels cuttherefrom depicting the foam panel construction of the present inventionin both its fully collapsed position and its fully extended position;

FIG. 10 which comprises FIGS. 10A and 10B are perspective view of afurther alternate embodiment of the foam panels of FIG. 12 shown in acollapsed, fully extended position; and

FIG. 11 which comprises FIGS. 11A and 11B are perspective views of analternate embodiment of the foam panel construction of the presentinvention shown in a collapsed, fully extended position.

DETAILED DISCLOSURE

By referring to FIGS. 1-11, along with the following detaileddescription, the preferred construction of several alternate embodimentsof the readily extendable/expandable foam panel construction of thepresent invention can best be understood. In this disclosure, althoughseveral alternate constructions and embodiment details are provided,further alternate configurations and constructions can be implementedwithout departing from the scope of the present invention. Consequently,it is to be understood that the following detailed disclosure isprovided for exemplary purposes only and is not intended as a limitationof the present invention.

In FIGS. 1-3, three alternate configurations of readilyextendable/expandable foam panel 20 of the present invention are shown.In each of these embodiments, readily extendable/expandable foam panel20 comprises foam panel member 21 and a plurality of expansion zones orcutout zones 22 formed therein. As shown, each expansion zone 22 extendsthrough foam panel 21, from the top surface thereof to the bottomsurface.

In the constructions depicted, each foam panel member 21 comprises agenerally rectangular shape defined by top edge 24, bottom edge 25, andside edges 26 and 27. In addition, for purposes of illustration,expansion zones 22 are depicted comprising substantially identicalshapes in each of the alternate embodiments. In this regard, eachexpansion zone 22 comprises a substantially crescent or half moon shape.Although this shape is depicted in the Figures, this shape is providedfor exemplary purposes only and, as fully detailed above, expansionzones 22 may comprise any desired size or shape.

As stated above, the only requirement is that each expansion zone 22comprises a separate and independent zone positioned in spacedrelationship to adjacent zones 22. Finally, when expansion zones 22 areformed in foam panel member 21, a fully interconnected lattice 23 offoam material is formed between expansion zones 22 in peripherallysurrounding cooperating relationship therewith.

In the embodiments depicted in FIGS. 1 and 2, substantially the entireavailable surface of foam panel 21 comprises expansion zones 22. InFIGS. 1 and 2, side edges 26 and 27 do not incorporate expansion zones22, while the embodiment in FIG. 1 also incorporates a plurality ofadditional longitudinally extending sections which are devoid ofexpansion zones 22. In addition, as clearly shown in FIGS. 1 and 2,expansion zones 22 are formed in foam panel member 21 extendingcompletely from top edge 24 to bottom edge 25, regardless of the areaswhich are devoid of expansion zones 22.

In the embodiment depicted in FIG. 3, expansion zones 22 are formed insections 31 and 32 of foam panel member 21, while the remainder of foampanel member is devoid of expansion zones 22. In addition, the cutoutzones or expansion zones 22 formed in sections 31 and 32 extend from topedge 24 to bottom edge 25 directly adjacent side edges 26 and 27.

As is evident to one having ordinary skill in the art, any desiredpattern of expansion zones 22 can be formed in foam panel 21 in order toachieve a desired readily extendable configuration. By incorporatingexpansion zones 22 which substantially cover foam panel 21 in itsentirety, the expandability or extendibility of foam panel 20 isoptimized. By employing a limited number of sections of expansion zones22, as depicted in FIG. 3, the overall dimensional extendibility of foampanel 20 is more limited.

Regardless of the configuration employed, readily extendable/expandablefoam panel 20 is capable of being dimensionally changed quickly andeasily in order to accommodate any desired overall linear distance ordimension. In this regard, by applying a force to side edges 26 and 27in an attempt to cause edges 26 and 27 to be spaced apart from eachother, a user is able to quickly and easily increase the overall widthof foam panel 20 to any desired dimension. As a result, by employing thepresent invention, foam panels are quickly and easily extended orexpanded to accommodate any desired dimension for use with theparticular product.

In FIG. 4, a typical mattress assembly 35 is depicted which incorporatesthe present invention. As shown, mattress assembly 35 comprises asupport base 36 on which inner spring assembly 37 is positioned. Asshown, inner spring assembly 37 comprises a plurality of helicallycoiled springs mounted in side to side, adjacent relationship with eachother. In this embodiment, mattress assembly 35 is completed by placingextendable/expandable foam panel 20 on the top surface of springassembly 37. Once this assembly is completed, the entire mattress isfinalized by securing any desired additional components thereto and thenperipherally surrounding the assembly with a cover of textile materialto form the desired product.

As is evident from FIG. 4, the ease of constructing mattress assembly 35using the present invention is readily achieved. As shown therein,extendable/expandable foam panel 20 is positioned on the top surface ofspring assembly 37 for providing the top supporting surface of thefinally constructed mattress. In completing the secure affixation ofextendable/expandable foam panel 20 with spring assembly 37, anydimensional variations between the surface area defined by springassembly 37 and extendable/expandable foam panel 20 are easilyaccommodated.

In this regard, once extendable/expandable foam panel 20 is placed onthe top surface of spring assembly 37, side edge 26 of foam panel 20 ismerely pulled to be coextensive with the terminating edge of springassembly 37. Once in the desired position, a portion of edge 26 isaffixed to the edge of spring assembly 37 by employing a fastener orclip 38. This process is repeated along the entire length of edge 26until the entire edge is affixed to spring assembly 37. Thereafter, asimilar process is employed with edge 27 in order to completely securefoam panel 20 to spring assembly 37.

As is evident from the foregoing detailed discussion by employingextendable/expandable foam panel 20 of the present invention foam panel20 is quickly and easily securely affixed to spring assembly 37 withassurance that the entire top surface of spring assembly 37 iscompletely covered by foam panel 20. In addition, the complete coverageof spring assembly 37 is achieved with ease and simplicity in both theinstallation and manufacture of foam panel 20.

In FIG. 4, mattress assembly 35 is depicted incorporating the componentsdetailed above. In addition to these components, namely foam panel 20,spring assembly 37, and support base 36, mattress assembly 35 alsoincorporates side edge guard/support number 39. In order to provide afinal construction which achieves inherent strength and rigidity alongthe side edge of the mattress, for reducing buckling over long-term useand providing support for individuals when sitting on the edge of themattress, most higher-quality mattress assemblies incorporate a sideedge guard/support member 39. As depicted, side edge guard/supportmember 39 is mounted about spring assembly 37, peripherally surroundingthe side edges thereof and being securely affixed thereto. In this way,the desired beneficial results are achieved.

In FIG. 5, an alternate embodiment of extendable/expandable foam panel20 is depicted. In this embodiment, foam panel 20 is constructed in amanner similar to the embodiment detailed above and shown in FIG. 1.However, in this embodiment, side panels 40 and 41 are formed as anintegral component of foam panel 20. By employing this embodiment of thepresent invention, side edge guard/support members 39 are not requiredand the material and labor needed to affix side edge guard/supportmembers 39 to mattress assembly 35 is completely eliminated.

By employing the embodiment of the present invention depicted in FIG. 5,side panels 40 and 41 are automatically installed at the preciselydesired location along the longitudinally extending side edges of springassembly 37. In this way, by securely affixing expandable/extendablefoam panel 20 to spring assembly 37, side panels 40 and 41 areautomatically mounted in the precisely desired position, providinginherent support, rigidity, and longevity to the resulting product.

By referring to FIGS. 6-8, along with the following detailed discussion,further alternate embodiments of the present invention can best beunderstood. As is fully detailed below, in these embodiments of thepresent invention, expandable/extendable foam panel 20 is constructed ina manner which enables the foam panel to become locked in its openingposition after it has been fully extended.

In this way, the panel members manufactured in accordance with thisembodiment of the present invention achieve a fixed dimension when fullyopened and extended, while also possessing a smaller, second dimensionwhen compacted into its original position. By employing this embodimentof the present invention, the resulting foam panel can be opened to itsfully extended position and then placed in cooperating association witha desired surface, without requiring affixation of the foam panel to theproduct in order to maintain the foam panel in the expandedconfiguration.

In FIG. 6, one configuration of extendable/expandable foam panel 20 ofthis embodiment of the present invention is depicted. In thisembodiment, readily extendable/expandable foam panel 20 comprises foampanel member 21 and a plurality of expansion zones 22 formed therein. Asshown, each cut of zone 22 extends through foam panel 21 from the topsurface thereof to the bottom surface.

In this embodiment, each expansion zone 22 comprises a uniqueconfiguration which has been specially designed to achieve a uniquelyconfigured lattice 23 of foam material which peripherally surrounds anddefines each expansion zone 22. In this regard, lattice 23 of foammaterial is configured to enable panel member 21 to be extended orexpanded in one direction in a manner which causes each cut of zone tobecome enlarged.

In this regard, this embodiment of the present invention operates in amanner similar to the embodiment detailed above. However, the uniqueaspect of this embodiment of the present invention provides lattice 23of foam material with a unique configuration which causes the lattice tobecome rigid or fixed in its configuration once panel member 21 has beenopened to a specific overall dimension. In this way, foam panel 20 iseffectively locked in its open position.

In achieving this configuration, lattice 23 of foam material isconstructed to possess a spring biasing force similar to the springforces possessed by foam panel 20 detailed above. However, in thisembodiment, lattice 23 is also constructed to automatically shift fromproviding a flexible, spring biasing force to being rigid, fixed, orlocked in its open position, preventing foam panel 20 from automaticallymoving into a compact position.

Foam panels 20 manufactured in accordance with this embodiment of thepresent invention are fully depicted in FIGS. 6 and 7. As shown therein,two alternate configurations for expansion zones 22 are provided.However, in each of these alternate embodiments, lattice 23 of foammaterial is constructed to become fixed or rigid whenever panel 20 hasbeen expanded beyond a particular dimension. As a result,extendable/expandable foam panels 20 are capable of being maintained ina fully compact position, as shown in FIGS. 6A and 7A, and extended orexpanded to an open configuration, as shown in FIGS. 8B and 7D. However,whenever foam panel 20 has been opened to its substantially full extent,as depicted in FIG. 7C, lattice 23 of foam material becomes rigid orfixed in its configuration, maintaining panels 20 in a substantiallyrigid, open position.

In addition, as shown in FIG. 6C, foam panel 20 is preferablyconstructed for simultaneously providing both a locked and unlockedconfiguration. As depicted, the upper and lower portions of panel 20have lattice 23 in its fully extended and locked position, while themiddle portion of foam panel 20 is not fully extended. As a result, theside edges of foam panel 20 become arcuately curved.

Due to the ability of lattice 23 to become automatically locked in itsfully extended position, the configuration depicted in FIG. 6C ismaintained, until a force is applied to panel 20 to return panel 20 intoits compact position. As a result, the dual locking, multi-purposeversatility nature of panel 20 is clearly evident.

When panel 20 is in the configuration depicted in FIG. 6C, lattice 23 ofthe foam material is effectively locked throughout panel 20. In thisregard, whenever the foam elements forming lattice 23 are expandedsufficiently to cause the elements to pivot beyond 180°, the elementsbecome locked. However, the amount of force required to reverse thelocked configuration varies with the position of lattice 23, with themost force being required when the foam elements of lattice 23 are fullyextended.

Although lattice 23 of foam material is constructed to maintain panel 20in a fixed, rigid, open position when panel 20 is fully extended,lattice 23 of foam material is also configured to be reversible.Consequently, whenever desired, the side edges above foam panel member21 can be advanced towards each other, causing lattice 23 of foammaterial to return to its original position, with expansion zones 22returning to their substantially closed and collapsed configuration. Inthis way, readily extendable/expandable foam panel 20 of this embodimentof the present invention can be employed for a wide variety of alternateapplications in its fully extended configuration, while also beingquickly and easily returned to its small, compact configuration forstorage or shipment.

This unique construction is fully depicted in FIG. 7, wherein foam panelportion 20 is depicted in four alternate extended positions in order toillustrate exactly how the “locking segments” operate. Once the lockableexpansion segments are created in foam panel 20, regardless of themanufacturing process, these segments are considered “at rest” (or in arelaxed state) as shown in FIG. 7A. As the two ends of foam panel 20 arepulled apart in opposite directions, the lockable expansion segmentsbegin to separate and open up. However, there is a spring force at work,which attempts to pull the segments back to a closed position (see FIG.7B). As the two ends of the foam panel are pulled even further apart,the lockable expansion segments reach a postion where they have pivotedto a mid-way point and the spring force begins to decrease as the foamsegments now begin to compress against each other with vertical force(see FIG. 7C). Now, as the expansion segments pivot past the mid-waypoint, the vertical force of the foam segments pressing against oneanother and begins to force the segments into a subsequently openposition (see FIG. 7D) and completely removes the original spring forcethat was present in FIG. 7B. The expansion segments are now “locked”into an open configuration (see FIG. 7D).

Another unique aspect of this embodiment of the present invention is thesubstantial expansion distance that can be achieved using the presentinvention. As diagrammatically depicted in FIG. 7, extendable/expandablefoam panel 20 is capable of being altered from a compact configuration(FIG. 7A) to an elongated, substantially enlarged configuration (FIG.7D). In addition, a plurality of alternate expansion distances can beachieved between the two extremes.

In this regard, it has been found that expansion distances rangingbetween every one foot width of foam panel 20, panel 20 can be expandedto a width ranging between about 2.25 and 2.8 feet in width. As aresult, one extendable/expandable foam panel 20 is capable of beingemployed for use with a wide variety of various products havingdifferent dimensions. Although the dimensions of the product may vary,the capability of foam panel 20 of the present invention to be adjustedto accommodate numerous alternate dimensions enables a single foam panelto be used with a wide variety of differently sized end products.

In FIG. 8, several alternate views are provided of a further alternatefoam panel product which is capable of enjoying the benefits achieved byextendable/expandable foam panel 20. In this embodiment, a water toy orfloat construction 50 is attained wherein extendable/expandable foampanel 20 incorporates longitudinally extending, cylindrically shapedfoam tubes 51 and 52 intergrally formed along the side edges of thepanel 20. By employing this construction, a float configuration isrealized which is capable of being quickly and easily converted from asmall compact configuration into an enlarged, fully extended, bodysupporting configuration for use as a pool water float.

As shown in FIG. 8, extendable/expandable foam panel 20 incorporates aplurality of expansion zones 22 forming lattice 23 of foam materialtherebetween. As detailed above, the size and shape of expansion zones22 are configured to establish lattice 23 of foam material which enablesfoam panel 20 to possess two separate and distinct properties orphysical characteristics.

One of the properties possessed by foam panels 20 of this embodiment ofthe present invention is a spring biasing force which actively attemptsto return foam panel 20 to its original compact position during itsinitial stages of being extended or expanded. However, whenever foampanel 20 has been extended or expanded to a pre-defined dimension, theconfiguration of lattice 23 of foam material created by expansion zones22 causes foam panels 20 to become locked, fixed, or rigid in its fullyextended or expanded position. In this way, the float construction 50,or any other resulting product, maintains a specific dimension wheneverpanel 22 has been fully extended.

As a result, the float construction 50 can be used in the desired mannerwith complete assurance that the overall width of the product will bemaintained throughout its use. Furthermore, when use has been completed,float construction 50 is returned to its original collapsed position bymerely exerting a closing pressure on the side edges of foam panel 20.In this way, expansion zones 22 return from a fully open position totheir collapsed, closed configuration, enabling float construction 50 tobe storable in its small, compact configuration.

By referring to FIG. 9, along with the following detailed discussion, analternate method for manufacturing extendable/expandable foam panels 20can best be understood. In this manufacturing method, an elongated foamprofile 60 is extruded using generally conventional foam profileextrusion equipment. In addition, in this embodiment, cuts, slits, oropen areas 61 are formed in foam profile 60 as an integral part of theextrusion process by forming the extrusion die in a desired manner. Byincorporating cuts, slits, or open areas 61 in foam profile 60, theentire foam profile 60 is capable of being extended or expanded in atleast one direction, since cuts, slits, or open areas 61 create or formthe desired expansion zones whenever foam profile 60 is extended orexpanded.

If desired, elongated foam profile 60 can be employed in theconfiguration achieved from the extrusion process. However, it has beenfound that this manufacturing method can be most effectively employed byforming a plurality of segments 65 from an elongated foam profile 60. Inthis regard, segments 65 are quickly and easily created by merelycutting elongated foam profile 60 perpendicularly to the central axisthereof, effectively achieving a cross-sectional segment 65 having adesired thickness.

As depicted in FIG. 9B, each cross-sectional segment 65 is easilyproduced and is capable of being quickly and easily extended or expandedby merely pulling the side edges thereof in opposite directions. In thisway, the overall width of section 65 is extended or expanded, whilecuts, slits, or open zones 61 formed therein are converted intoexpansion zones 67, with lattice 68 of foam material peripherallysurrounding expansion zones 67. In the configuration depicted in FIG. 9,cuts, slits, or open zones 61 are constructed with the design detailedabove which achieves expansion zones 67 that are automatically convertedfrom a construction having an inherent spring biasing return force to aconstruction which when fully extended becomes locked In its openposition.

In FIG. 10, a further alternate embodiment of the present invention isdepicted. In this embodiment, elongated foam profiles 60 are constructedas detailed above and shown in FIG. 12, and then subsequently welded inadjacent, side to side relationship with a cooperating elongated foamprofile 60. The resulting product is depicted in FIG. 10, wherein threeseparate elongated foam profiles 60 have been welded to each other.

Thereafter, in an alternative embodiment of the present invention,elongated sections of the resulting welded profile are formed,effectively achieving an elongated foam cross-section having threesections 65 welded to each other. In this way, a final structure isrealized which possesses any desired length. As a result, an enlargedlongitudinally extending product is achieved having virtually anydesired dimension which is able to be manufactured both expeditiouslyand economically.

Finally, in FIG. 11, a further alternate embodiment ofexpandable/extendable foam panel 20 is depicted. In this embodiment,foam panel 20 is constructed with cuts, slits, and open zones 70 formedin foam panel 20 extending both horizontally and vertically. Byemploying this construction, foam panel 20 can be extended or expandedin two mutually exclusive directions, depicted in FIG. 11 as bothhorizontal expansion and vertical expansion. Although FIG. 11 depictscuts, slits, and open zones 70 being formed perpendicular to each other,any desired angular relationship can be employed without departing fromthe scope of this invention.

It will thus be seen that the objects set forth above, among those madeapparent from the preceding description, are efficiently obtained and,since certain changes may be made in the above article without departingfrom the scope of the invention, all matter contained in the abovedescription or shown in the accompanying drawings shall be interpretedas illustrative and not in a limited sense.

It is also to be understood that the following claims are intended tocover all of the generic and specific features of the invention hereindescribed, and all statements of the scope of the invention which, as amatter of language, might be said to fall therebetween.

1. A mattress, comprising: an innerspring having a perimeter; one ormore foam panels adjacent to at least a portion of the perimeter of theinnerspring, each of the one or more foam panels comprising: anelongated member disposed along a longitudinal axis; and at least oneexpansion zone integrally formed in the one or more foam panels; whereinthe at least one expansion zone is configured to expand in the directionof the longitudinal axis of the at least one foam panel to allow alength of the foam panel to be expanded up to an expansion distance ofthe at least one expansion zone and contracted.
 2. The mattress of claim1, further comprising one or more channels disposed through theelongated member.
 3. The mattress of claim 1, wherein the at least oneexpansion zone is comprised of a plurality of expansion zones integrallyformed in the foam panel and forming a plurality of openings in the foampanel.
 4. The mattress of claim 1, wherein the plurality of expansionzones are comprised of a plurality of apertures.
 5. The mattress ofclaim 4, wherein a first aperture among the plurality of apertures isdisposed on a top edge of the foam panel, and a second aperture amongthe plurality of apertures is disposed on a bottom edge of the foampanel.
 6. The mattress of claim 4, wherein the plurality of aperturesform apertures along length axes of the elongated member between a topedge and a bottom edge of the foam panel.
 7. The mattress of claim 4,wherein the plurality of apertures are disposed along the longitudinalaxis of the foam panel.
 8. The mattress of claim 4, wherein theplurality of apertures are disposed along a plurality of longitudinalaxes of the foam panel.
 9. The mattress of claim 4, wherein theplurality of apertures are comprised of a plurality of cuts.
 10. Themattress of claim 4, wherein the plurality of apertures are comprised ofa plurality of slits.
 11. The mattress of claim 1, wherein the at leastone expansion zone is comprised of a plurality of expansion zones. 12.The mattress of claim 11, wherein each of the one or more foam panelsfurther comprises at least one interconnected lattice of foam disposedbetween adjacent expansion zones among the plurality of expansion zones.13. The mattress of claim 1, wherein the one or more foam panels eachcomprises a substantially flat planar body including a top surface and abottom surface, and defined by a top edge, a bottom edge, a first sideedge, and a second side edge.
 14. The mattress of claim 3, wherein theplurality of expansion zones comprises a first expansion zone adjacentto a second expansion zone, each of the plurality of expansion zonesextending from one edge to an opposite edge of the planar body.
 15. Themattress of claim 14, wherein the first expansion zone comprises a firstportion of the plurality of apertures in a first pattern of apertures,the first portion separately expandable and contractible in a directionorthogonal to a first geometric line, at least a portion of each of thefirst portion disposed within the first geometric line when the firstportion is fully contracted, the first geometric line extending from theone edge to the opposite edge of the planar body.
 16. The mattress ofclaim 15, wherein the second expansion zone comprises a second portionof the plurality of apertures in a second pattern of apertures, thesecond portion separately expandable and contractible in a directionorthogonal to a second geometric line, at least a portion of each of thesecond portion disposed within the second geometric line when the secondportion is fully contracted, the second geometric line extending fromthe one edge to the opposite edge of the planar body.
 17. The mattressof claim 16, wherein the first pattern of apertures comprises adifferent aperture shape than the second pattern of apertures, and thefirst geometric line and the second geometric line are parallel to eachother and parallel to the top surface.
 18. The mattress of claim 4,wherein the plurality of apertures is further defined as being formed ina planar body in juxtaposed, spaced, adjacent relationship to eachother, effectively forming at least one expansion zone which enables thefoam member to be expandable and contractible in the expansion zone. 19.The mattress of claim 4, wherein the plurality of apertures are furtherdefined as being formed in a planar body in juxtaposed, spaced, adjacentrelationship to each other substantially throughout the entire planarbody.
 20. The mattress of claim 4, wherein the plurality of aperturesare further defined as comprising a shape or configuration comprising atleast one selected from the group consisting of circles, slits, halfmoon shapes, quarter moon shapes, triangles, trapezoids, rectangles,ovals, and ellipses.
 21. The mattress of claim 13, wherein the planarbody is a product of any desired width produced by employing continuousroll forming.